Multi-Objective Optimization of the Cutting Forces in Turning Operations Using the Grey-Based Taguchi Method

Abstract

This study investigated the multi-response optimization of the turning process for an optimal parametric combination to yield the minimum cutting forces and surface roughness with the maximum material-removal rate (MRR) using a combination of a Grey relational analysis (GRA) and the Taguchi method. Nine experimental runs based on an orthogonal array of the Taguchi method were performed to derive objective functions to be optimized within the experimental domain. The objective functions were selected in relation to the parameters of the cutting process: cutting force, surface roughness and MRR. The Taguchi approach was followed by the Grey relational analysis to solve the multi-response optimization problem. The significance of the factors on the overall quality characteristics of the cutting process was also evaluated quantitatively using the analysis-of-variance method (ANOVA). Optimal results were verified through additional experiments. This shows that a proper selection of the cutting parameters produces a high material-removal rate with a better surface roughness and a lower cutting force.